Process for producing acetylenes



Feb. 16, 1965 1-1.5. KENNEDY 3,169,915

PROCESS 'FOR PRODUCING ACETYLENES Filed July 25, 1960 Y z Sheets-Sheet 1 1'8 MM /5 36 W I rr W INVENTOR. 53 HARRY E. KENNEDY ATTORNEY Feb. 16, 1965 H. E. KENNEDY 3,169,915

PROCESS FOR PRODUCING ACETYLENES Filed July 25, 1960 2 Sheets-Sheet 2 INVENTOR HARRY E. RNNEDY ATTO RNEY United States Patent 3,169,915 PRUCESS FOR PRODUCING ACETYLENES Harry E. Kennedy, Berkeley, Calif., assignor to Union Carbide Corporation, a corporation of New York Filed July 25, 1960,-Ser. No. 45,095

v9 Claims. (Cl. 204-471) This invention, relates to the conversion of hydrocarbons; More particularly, this invention relates to the production of acetylenes and other gases by the decomposition of hydrocarbons in anelectric arc process.

This application is a continuation-in-part offmy copending application Serial No. 794,936,Ifiled February 24, 1959, now abandoned, and entitled Process for Pro-1 ducing Acetylenes.

Because of its high reactivity, acetylene is greatly valued for welding and chemical synthesis. The economic production of acetylene hasbeen the subject of extensive research and development for many years.

Acetylene was first producedcommercially by the calcium carbide process. 'Calcium carbide is costly to ship and the acetylene yield is only about 0.4 pound of acetylene per pound of calcium carbide. Large acetylene plants using calcium carbide are usually adjacent to the carbide furnaces, which must be located in areas Where limestone, coal and electricity are available in large quantities. The dispos l; O'fthe by-product lime from such a a process presents aserious problem. 4 ed directly fromlhydro carbons by-decompo sition'jin' an electric'a'rc. Twosuch Acetylene can also beobtai methods have some commercial interest the Schocli Elec tric Discharge Process of the Universityof Texas Bureau ofrlndustrial Chemistry, and 'the Von Ediger Process,

which isdescribed in US; PatentNo. 2,632,731. The Schoch process employs a frotar'y blower electrode todecomposeYhydrocarbons :in the vapor, phase in anielectric arc discharge; "It has'not'been used commercially because the acetylene content of the cracked rotary elecgasis low, high voltages are needed and the trocle is expensive to build and operate; j

' The Von Ediger process yields high acetylene concentrations by exposing liquid hydrocarbons to intermittent electric arcs'generated between electrically conductive particles supported loosely in shallow layers on an electric grid beneath the liquid. The electric grid is com posed of carbon electrodespwhich areiparallel rodsof alternate polarity.-- Current havinga potential of 300 to 1,000 volts is passed from onerod through the conductive particles to an adjacent rod. .Small inte'rmittent arcs are thus formed between the loose particles. The

cracked gas formed in one of these arcs blows the 'conductive particle away and the'ar cis extringuishd The Von Ediger process has not found commercial use, probably because of excessive erosionof the conducting particles and electrodes. v v i The primary object of this invention is to produce acetylene economically by electric arc cracking of fluid hydrocarbons in-a'continuous'process. i i It is a further object of thisinvention to provide electric arc electrodes which destructible. V

Other objects andjadvantages of this invention will appear from the following description andv appended claims,

are self-restoring and non keroseneor diesel or fuel oils.

3,l69,9l5 Patented Feb. 16, 1965 According to this invention, a process for converting hydrocarbons comprises surrounding liquid electrodes with fluid hydrocarbons, and cracking the fluid hydrocarbons by striking intermittent electric arcs between the alloy generally composed of lead, tin and bismuth; More specific descriptions of this latter-alloy can be found in almost any well-known technical handbook, as for example Perrys Chemical Engineers Handbook, 1950 edition. f While anyof these conductive liquids may be employed, the use of two liquid electrodes of mercury is preferred for the practice of this invention. This is because mercury is a liquid at ambient temperature and, as an element, is of invariant composition. Morever'its relatively low boiling point permits separation by vaporization from some process or reaction mixtures such as heavy carbon sludges or very heavy oils.

While the liquid mercury electrodes may be formed by or employedfin any suitable manner, the procedure most preferred for this invention" is that in which one-0f the liquid electrodes, in the form of a pressured jetor stream,

' passes into the other electrode, which is in the form of a liquid pool. This arrangement has been found'to give asmooth-burning are with the character'mostsatisfactory to provide steady, smooth operation, high cracked gas production, and high acetylene yields and power efiiciem' cie s. -Because of its dimensional stability, the. arc is easy" to adjust and to maintain at optimum operating temperatures. I

Within the limits of practicality, any fluid hydrocarbon can be cracked by the processof this invention: However, this invention is particularly applicable to cracking those liquid hydrocarbonsassociated with or obtainable from petroleum. These include the crude petroleum oil itself, straight run or cracked naphtha, natural gasoline,

Gaseousfeedstocks can also becracked by the process of this invention. Exemplary of those gaseous feed stocks usable in the practice of'this invention are those comprised of the natural gas hydrocarbons such as methane, ethane, propane apdbutane; the lower alkenes such as ethylenegj'propyl'ene'and butyleneg and some of the lower boiling components of. natural :gasolin'e. that can Lbe vaporized and cracked in the the-voltage of the are formed between the electrodes can vary from to more than 5000 volts, while the current 1 employed in the process of this invention can be either alternating with frequencies of between 25 and'6.0- or higher cycles, or direct current.

However, for the practice of this invention a pressure of between 2 p.s .i.g. and 10 p.s.i.g. and a temperature of gas phase, such as 'penbetween 150 C. and 350 C. is preferred for commercial usages. Similarly, a voltage of about 1000 volts and an alternating current of about 60 cycle frequency is also preferred.

It is to be understood that these preferred reaction conditions are relative and will vary according to such factors as efiiciency desired and type of hydrocarbon feed. For example, should it be desirable to maintain the reaction at the hottest possible level, the reaction temperature is limited by the boiling point of the mercury electrodes, i.e. 357 C., and the boiling point of the hydrocarbon oil. Similarly, for pilot 'or experimental processes as shown in the examples which follow, pressures of about atmospheric or the like may be employed.

The invention will now be discussed in detail by reference to the drawings, in which:

FIG. 1 is a partially cross-sectional, elevational view of a preferred form of apparatus for practicing the invention.

FIG. 2 is a cross-sectional, elevational View of the liquid metal nozzle used in the apparatus of FIG. 1.

FIG. 3'is a partially cross-sectional, elevational view of another embodimentofthe apparatus for practicing the invention.

FIG. 4 is a cross-sectional, elevationalenlargement of the high voltage receiver shown in FIGJ3.

FIG. 5 is a cross-sectional, elevational enlargement of the ground receiver shown in FIG. 3.

Referring now to FIG. 1, the preferred apparatus for practicing the invention includes a metal reactor containing a hydrocarbon liquid oil 11 maintained at the level A and floating on an electrically conductive liquid 12 maintained at the level B. The reactor 10 and all metal parts connected thereto are grounded to a supporting metal frame, not shown, which is connected tothe ground side of the electric arc circuit by an electric cable.

Conductive liquid 12 in the base of the reactor passes through suction pipe 13, enters pump 14 and is pumped through discharge pipe 15, the upper portions 16 of which is flexible metallic tubing. The flexible discharge pipe 16 is attached to a jet nozzle 1'7 through which a jet of conductive liquid issues downward into the reactor. Diaphragm pressure gauge 18 indicates the pressure in the flexible discharge tubing 16. The nozzle 17 is supported by a movable rod 19, which passes through a packing gland 20in the top flange 21 of the reactor. A handle 22 attached to themovable rod 19 is useful in adjusting the nozzle 17 up or down.

The conductive liquid is ejected from .the nozzle 17 downward into the hydrocarbon liquid 11 in which the nozzle is immersed. The conductive liquid falls into a metal receiver 23, hereafter referred to as the hot cup, which is supported by metal strips 24 bolted to metal studs 25. The studs are welded to the tips of automotive spark plugs 26, which are screwed into metal bosses in the wall of the reactor. Thus, the spark plugs 26 support the hot cup 23 and electrically insulate it from the grounded metal reactor and'conductive liquid nozzle 17. Electric cables 27 connect the spark plugs to the high voltage side of the electric arc circuit so that an electricalipotential can be applied between the hot cup and the electrically-grounded, descending stream of conductive metal liquid.

The jet nozzle 17 is shown in detail in FIG. 2. Conductive liquid enters a chamber 28 in the metal distributor piece 29 through inlet 30 and passes to nozzle tip 31. The liquid leaves the nozzle through a small orifice 32, .015inch to ;050 inch or larger in diameter.

Conductiveliquid entering the hot cup 23 forms a pool therein and overflows through the hydrocarbon liquid 11 to the cone at the base of the reactor 10, thus completing its flow cycle through the apparatus.

The apparatus of FIG. 1 may be used with any electrically conductive liquid metal or alloy, such as mercury or Woods metal. For example, electrical resistance heat- Cit 4 ing strips (not shown) can be fastened to the external Walls of the reactor and sheathed electric heating tubes 33 in the conductive liquid piping can be used to raise the temperature of Woods metal contained in the reactor to its melting point of about 70 C. to 75 C.

If an electrical potential of 100 to 1,000 volts, for example, is applied between the high voltage cable 27 and the cable to which the reactor 10 is grounded, electric current will pass between the conductive liquid stream issuing from the jet nozzle 17 and the conductive liquid in the hot cup 23 below. When the length of the metal stream from the nozzle to the cup is properly adjusted by moving the nozzle, an electric are or arcs will strike in the hydrocarbon liquid between the conductive liquid droplets in the bottom part of the falling stream. If the nozzle 17 is sufficiently raised, the electrical circuit can be broken. Conversely, a short-circuit can be obtained by lowering it sufliciently.

The conductive liquid descending from the nozzle 17 through the oil is broken into a stream of falling droplets by the shearing action of the oil. Each droplet is urrounded by a film of oil which resists the flow of electric current. When the length of the stream of droplets is properly adjusted, their combined resistance can be bridged by the voltage across the hot cup and the jet nozzle, and an electric are or arcswill strike. The are vaporizes and decomposes some of the surrounding hydrocarbon liquid and, if this liquid is fuel or crude oil, or kerosene, then acetylene, hydrogen, carbon black (finely divided carbon), and small amounts of other hydrocarbons, such as methane and ethylene will be formed. The rapid, almost explosive formation of hot gases vaporizes and blows apart the conductive liquid stream and extinguishes the arcs struck. The surrounding oil then quenches the gases, cools them rapidly to the oil temperature of, for example, 100 C. to 200 C. and they pass upward to the surface of the oil. Rapid quenching i essential if high acetylene concentration is desired in the cracked gas. As

the formed gases pass upward, additional conductive liquid approaches the pool in the hot cup and new arcs are struck.

'Whena study is made of voltage and current variations in the arc circuit with an oscilloscope, the extremely brief contact times devoted to arcing and reaction quenching are readily apparent. Both arcing and quenching occur in less than .005 second, and probably in less than .001 second.

Most of the carbon black remains in the hydrocarbon liquid but some will pass upwardly with the formed gases. Referring again to FIG. 1, the cracked gas, essentially acetylene and hydrogen, leaves the reactor through the outlet pipe 34 and passes to a condenser and entrainment separator (notshown) where it is cooled and vaporized oil is removed before. the gas enters gas metering and sampling equipment. Oil from the condenser and entrainment separator drains back to the reactor through returnpipe 35. Acetylene in the cooled, cracked gas can be recovered in any ofseveral gas scrubbing systems familiar to those versed in the art.

Most of th'ecarbon black formed settles to the bottom of the reactor whereit is withdrawn as a mixture of oil and sludge through the outlet 36. The sludge is removed in equipment not shown and the recovered oil is returned to the reactor through the tangential inlet pipe 37. Conductive liquid entrained in the carbon sludge can be recovered and'returned to the reactor and the carbon can be recovered for sale.

The reactor is provided with auxiliary connections, not shown, for the measurement of pressure, temperature, liquid level, etc. Multiple streams of conductive liquid may be utilized instead of only a single stream as shown in FIG. 1.

Another embodiment of the invention is illustrated by the apparatus shown in FIG. 3. In FIG. 3, the metal reactor 38 contains the liquid hydrocarbon oil which is to be decomposed. The reactor 38 and all metal parts connected to it are connectedto the ground side of the electric arc circuit by electric cable 39. The level of the liquid hydrocarbon is maintained at C, and the'level of the electrically conductive liquid is maintained at D. The hydrocarbon floats on the conductive liquid in the conical section of the reactor 38.

The conductive liquid at the bottom of the reactor 38 flows through suction pipe 40 and into pump 41, from which it is pumped upward through pipe 42 and enters the top of the reactor through pipe nipple 43.. 'The mercury then falls into a metal receiver 44, hereinafter referred to as the circuit-breaker cup, which is supported from the top walls of the reactor by metal studs 45. The bottom of the cup is perforated with a multiplicity of holes 46, which can be 0.030 inch to 0.80 inch in diameter, or larger. The mercury passes through the holes 46 and falls in small streams to a second receiver 47 below, hereinafter referred to as the hot cup.

The hot cup 47 comprises a metal frame which supports shielding material made of a temperature-resistant, electrically insulating substance such as a tetrafluoroethylene polymer; Cup 47 is shown in detail in FIGURE 4 and will be more fully described later.

The hot cup 47 is supported by metal studs, one of which is shown at 48, passing through the metal side walls of reactor 38 and electrically insulated from the reactor walls by ceramic insulator 49. The metal supporting stud 48 can conduct an electric potential to the hot cup 47 and 'to the conductive liquid within it. Electric cables, one of which is shown at 50, supply current to the studs of 100 to 1000 volts or higher;

The distance between cups 44 and 47 is such that the falling mercury streams are broken into mercury drop-.

lets by the, shearing action of the oil through which the streams must fall. The dielectric strength of oil surrounding these droplets is high enough so that electric current will not be conducted between the circuit-breaker cup 44 and the hot cup 47.

The bottom of the hot cup 47 is constructed of an electrically insulating plastic such as a tetrafluoro-ethylene polymer and is perforated with a multiplicity of holes 52. There are fewer holes in the bottom of the hot cup 47 than in the bottom of the circuit-breaker cup 44 and the sides of the hot cup contain overflow holes 51.

These allow a constant head of conductive liquid to be' maintained above the hole 52 in the bottom of the hot cup 47 without the necessity of fine adjustment of the pumping rate.

A shielding tube 53 surrounds the space above the circult-breaker cup 44 and the space between cup 44 and the f resistant, electrically insulating material, and will be more fully described later. The metal frame of the ground cup is bolted to and supportedby a movable metal rod 55 which passes through the reactor cover flanges 56, through packing gland 57 and is fastened to the lever arm 58. A ground cable 59 connects the metal rod to the main ground cable 39. The ground cup 54 can be raised or lowered by movement of the lever 58, so as to adjust the distance between the hot cup 47 and the ground cup 54. Conductive liquid streams falling from the ,hot cup 47 will fill the ground cup 54 since the bottom of the ground cup is unperforated. Conductive liquid will then umummmnmmm...

flow over the sides of the ground cup and fall to the bottom of the reactor 38, at liquid level D.

The internal bottom of the ground cup 54 is a metal plate which is bolted to the metal frame of the cup with a metal screw 75 so that the metal plate and the conductive liquid within the cup are at ground potential with regard to the electric arc circuit. The lower part of the supporting rod 55 is shielded by a tube60 of a temperature-resistant,electrically insulating material to prevent any possibility of prematurely gr'oundingthe high voltage conductive liquid streams' falling from the hot cup 47.

FIGURE 4' shows possible details of the hot cup 47 but operability of the invention is not limitedto the particular embodiment shown.

In FEGURE 4, the circular frame 61 is made of a strong, electrically conductive material such as steel. It contains grooves into which metal support studs 48 can be tightened so as to conduct electric current into the hot cup and thus to the conductive liquid contained in the cup. The upper rim 62 of the hot cup is a circular ring made of a high temperature-resistant, electricallyinsulating material and the bottom 63 of the cup is made of a similar material. The bottom 63 of the cup con tains holes 52. of about 0.030 inch to 0.080 inch in diame ter and through which the conductive liquid streams fall to the ground cup below. The upper rim and bottom of the cup, being non-conductive, are not eroded by stray arcing which might occur from spattering of the mercury liquid above or below the hot cup. The side holes 51, which can be 0.100 inch to 0.200 inch in diameter, permit excess conductive liquid to overflow to the bottom of the reactor.

The ground cup 54, shown in detail in FIG. 5,1125 general features similar to the hot cup except that the conductive liquid leaves the ground cup by flowing over its sides. The circular frame 64 is made of a strong, electrically conductive material such as steel, and is bolted to a supporting plate 65 and-rod 55 of the same material. The frame 64 is shielded by a liner 66 of temperature-resistant, electrically insulating material. A circular metal plate 67 covers the inside bottom of the cup and is exposed to the conductive liquid contained therein. The'metal support rod 55 is connected to the ground side of the electric circuit and the conductive liquid within the cup is thereby also grounded through metal plate 67- and metal screw 75 to the supporting plate 65.

In the operation of the invention as exemplified in the the two cups is properly adjusted. Ifth e ground cup is I raised suficiently, a short-circuit will occur and if it is lowered, the electric circuit will be broken.

An electric arc is formed when the lengths of the mercury streams falling through the hydrocarbon breaks the streams into mercury droplets whose resistance when surrounded by the'hydrocarbon is equivalent to a spark gap which can be bridged by the impressed voltage to form an electric arc. The are vaporizes and decomposes some of the surrounding hydrocarbon to form acetylene, hydrogen, carbon black (finely divided carbon), and small amounts of lower molecular weight hydrocarbons, such as ethylene. The explosive formation of the hot gases extinguishes the arc and the surrounding oil rapidly cools the gases to the oil temperature, which can be 40 C. :to 200 C. This rapid quenching is vital to the production of high acetylene concentrations in the cracked '7 gas. The cooled gases bubble upward to the surface of the oil, additional falling mercury droplets approach the grounded mercury in the ground cup 54., other arcs are struck and the process is repeated.

Some of the very fine carbon black formed stays in the gas which bubbles to the surface of the oil, but most of the carbon remains in the oil. The cracked gas, which is mostly acetylene and hydrogen, leaves the reactor 33 through gas outlet pipe 68 and enters the entrainment trap 69. Entrained oil, if any, returns to the reactor through drain line 70 and the cracked gases leave the trap through the gas outlet line 71 to gas metering and sampling equipment and an acetylene recovery system (not shown).

The reactor and entrainment trap are provided with auxiliary tap connections such as 72 and 73 for the measurement of pressure, temperature, liquid level, etc. A drain tap 74 is provided on the lower side of the reactor for the removal of an oily carbon-mercury sludge which forms during the operation. This sludge can then be treated for mercury and carbon recovery.

The reactor described above can produce cracked gas containing at least 30% acetylenes when cracking kerosene oil, or heavier oils such as crude oil or fuel oil, at atmospheric pressure, temperatures of 40 C. to 200 C. and impressed voltages of 200 volts to 600 volts with 60 cycle A.C. current. Under reduced pressures of from to pounds per square inch absolute, the reactor has produced cracked gas containing at least 33% acetylenes.

The voltages, pressures and temperature previously set forth are by way of preference only; and it is to be understood that the invention will operate under other condi- .tions. For example, pressures above or below atmospheric can be used and temperatures up to within a few degrees of the boiling point of the hydrocarbon oil may be employed. Direct current or alternating current with any frequency may be used and a wide range of voltages can be used, although best results are obtainable with potentials over 100 volts.

Acctylenes obtainable in the cracked gas decrease below where lower. molecular weight oils are cracked. For example, heptane produces 27% acetylenes under conditions at which kerosene will give 30% acetylenes.

Where lube oil or kerosene is cracked, about half the carbon is removed as acetylene, one-fourth to one-third as higher acetylene homologs and ethylene, one-tenth as carbon black and the rest as methane and other hydrocarbon gases. Typical results for these two feed stocks are tabulated below:

1 Mostly methane, and C; and C4 hydrocarbons.

Contact trays may be used as a means of contact between the conductive liquid electrode and the conductive liquid pool instead of the [apparatus arrangement shown in FIG. 3. Also, intersecting mercury streams, one stream being at ground potential and the other at an elevated voltage, can be used. Also, a metal or carbon rod in intermittent contact with a pool or stream of mercury, or a mercury stream falling onto a metal or carbon electrode give satisfactory results. As indicated previously, other low-melting metals such as lead, tin or low-melting eutectic alloys such as Woods metal can be used as the conductive liquid instead of mercury.

The invention may be further illustrated by the following exarnplcs, all of which were made employing 60 cycle alternating current.

EXAMPLE 1 1.5 gallons (10 pounds) of liquid kerosene was charged to an apparatus of the type shown in FIGURE 1. Two liquid mercury electrodes were employed, one of the liquid electrodes being sprayed as a pressure jet into the other electrode which was in the form of a pool. The kerosene feed was disposed about the liquid electrodes. A pressure of 0.2 p.s.i.g. and a temperature of C. was maintained within the reactor. An intermittent electric arc was thereupon struck between the electrodes, the arc gap being 1% inches measured from the tip of the jet nozzle employed to the mercury pool below. To form the are an impressed voltage of 450 volts and an arc current of 50 to 60 amperes was used.

After being subjected to intermittent arcs for a period of approximately 30 minutes, 1.1 pounds of the kerosene feed was found to be cracked. Carbon and hydrogen balances were used to calculate the weight of oil decomposed per cubic foot of cracked gas. The oil consumption was then calculated from the cracked gas rate which was 50 cubic feet per hour. The following units were calculated from a sample analysis of the cracked gas using carbon-hydrogen balances and are tabulated below:

Table 1 Yield Per Pound of Vol. Kerosene Cracking products percent Pound Cubic Ft.

Hydrogen 49. 8 059 11. 4 Methane 4. 6 043 l. 1 Acetylene- 26. 6 411 G. 1 Ethylene 7. 9 131 1.8 than 0. 7 012 0. 2 Methyl acetylene 1. 2 .028 0. 3 Propylene 2. 1 052 0. 5 Propane 0. 2 005 Diacetylene 3. 5 103 0. 8 Vinyl acetylene...- 0.6 018 0.1 Butadiene 1.0 032 0. 2 Butenes 0. 9 030 0. 2 CsS and higher. 0.9 037 0. 2 Carbon (calculated) 039 EXAMPLE 2 1.5 gallons (ll pounds) of heavy lube oil Was charged to an apparatus of the type shown in FIGURE 1. A pressure jet of liquid mercury, was sprayed into a liquid mercury pool in the manner described heretofore, thereby forming two liquid mercury electrodes. The feed stock of heavy lube oil was disposed about the liquid electrodes. A pressure of 0.4 p.s.i.g. and a temperature of C. was maintained within the reactor. An intermittent electric arc was thereupon struck between the electrodes, the arc gap being 1 /2 inches measured from the tip of the jet nozzle employed to the mercury pool below. To form the are an impressed voltage of 450 volts and an arc current of 40 amperes was used. After being subjected to intermittent arcs for a period of approximately 30 minutes, 0.75 pound of the heavy lube oil feed was found to be cracked. Carbon and hydrogen balances were used to calculate the weight of oil decomposed per cubic foot of cracked gas. Then the oil consumption was calculated from the cracked gas rate The results obtained sene feed was found to have beencracked at the rate of 2.0 pounds per hour. Cracked gas analysis and car- Table II hem and hydrogen balances were used to calculate the weight of kerosene decomposed per cubic foot of cracked v t Yleld Per Pound of gas formed. Then the kerosene consumption rate was Vol. Lube oil cracked Cracking products percent calculated from the cracketd gas rate which was 40 cubic Pound Cum Ft. feet per hour. The results obtained are tabulated below:

, 7 7 V v I Table IV Hydrogen 54. 7 068 13. 2 Methane. 3.7 .037 0.9

27. 8 449 6.7 Yield Per Pound oi 6.5 .114 1.6 Vol. Kerosene Cracked 0, 3 00 0, 1 Cracking products percent Methyl acetylen 0.9 .022 0.2 Propylene q 1. 2 032 0. 3 Pound CllblC Ft. Propane Diacetylene 2.8 .088 0.6 Vinyl acetylene O. 6 016 0. 1 r 3 5 8. 7 Bntadiene 0.5 .017 0.1 t ane 9.8 .081 2.0 B t 0 4 014 0. 1 Acetylene 19. 3 259 3. 9 05's and higher 0. 7 .031 0. 2' Ethylene- 14. 4 .209 2. 9 Carbon (calculated) .106 Et e--- 0.8 .012 0.2 Propylene 4. 5 098 0. 9 100. 0 1.000 24. 1 P opane 0. 3 .007 o. 1 C4S and higher 7.6 .209 1. 5 Carbon (calculated) .080 EIQXMPLE 3 100.0 1. 000- 20.2 1.5 gallons (10 pounds) of liquid kerosene Was charged to an apparatus of the-type shown in FIGURE 1. A Mostly uusaturates. pressure jet of liquid Woods metal as sprayed into a EXAMPLE 5 liquid Woods metal pool in the manner described heretofore, thereby forming two liquid Woods metal electrodes. The feed stock of liquid kerosene was disposed about the liquid electrodes. Atmospheric pressure and a temperature of 120 C. was maintained within the reactor. An intermittent electric arc was thereupon struck between the electrodes, the arc gap being 1 inch measured from the tip of the jet nozzle employed to the Woods metal pool below. To form the are an impressed voltage of 400 volts and an arc current of 20 to amperes was used.

After being subjected to intermittent arcs the kerosene feed was found to be cracked at the rate of 0.4-5 pound per hour. Cnacked gas analysis and carbon and hydrogen balances were used to calculate theweight of kerosene decomposed per cubic foot of cracked gas formed.

Then the kerosene consumption rate was calculated from the cracked gas rate, which was 10' cubic feet per hour.

The resultsobtained are tabulated below:

Table III A l I Yield Per Pound of Vol. Kerosene Cracked Cracking products percent Pound Cubic Ft.

Hydrogen- 4s. 7 05s 10. 9 Methane 4. 9 045 1.1 Acetylene- 27. 1 406 6. 1 Ethylene- 10. 0 162 2. 2 Ethane 0. 8 014 0.2 Propylene. 1 2. 5 060 0. 6 Propane 0.2 00.5 0. 1 04's and h 5. 8 179 1. 3

(mostly uusaturate) Carbon (calculated) 07 3 EXAMPLE 4 1 1.5 gallons (10'pounds) of liquid kerosene was charged to an apparatus of the type shown in FIGURE 1. A pressure jet of liquid Woods metal was sprayed into a liquid Woods metal pool in the manner described heretofore, thereby forming two liquid Wood's metal electrodes. The feed stock of liquid kerosene was disposed about'the liquid electrodes. A pressure of 0.2 p.s.i.g. and a tempenature of 170 C. was maintainedwithin the reacton:

An intermitent electric arc wasthereupon struck between the electrodes, the are gapv being 1 inch measured from the tip of the jet nozzle employed to the Woods met-ail pool below. To form the are an impressed voltage of 400 volts and an arc current of 60 to 80 aniperes was used.

- After being subjected to intermittent arcs the. keroheavy lube oil was disposed about the liquid electrodes. An atmospheric pressure and a temperature of about] 125 C. was maintained Within the reactor. An intermittent electric arc was thereupon struck between the electrodes, the arc gap being 1 inch measured from the tip of the jet nozzle employed to the mercury pool below. To form the arc an impressed voltage of 360 volts and an arc current of amperes was used.

After being subjected to intermittent arcs for a period of approximately 60 minutes, 5.3 pounds of the heavy lube oil feed was found to be cracked. The weight of oil decomposed per cubic foot of cracked gas was calculated from a cracked gas analysis using carbon and hydrogen balances. Then the lube oil consumption was calculated from the cracked gas rate, which was cubic feet per hour. The results obtained are tabulated below:

Table V Yield Per Pound of Vol. I Lube Oil Cracked Cracklng products percent;

Pound Cubic Ft.

Hydrogen 51. 9 061 11. 8 Methane.-- 4.. 9 045 1. 1 Acetylene 27. 4 421 6. 3 Ethylene-.. 7. 7 127 1. 8 Ethane 0. 4 007 0. 1 Methyl acetylene 0. 9 .021 0.2 Propylene 1. 5 037 0. 3 Propane 0. 2 005 Diacetylene. 2. 0 059 0. 5 Vinyl acetylene 0. 5 015 0. 1 Butadiene 0.8 026 0. 2 .Butenes O. 6 U20 0. 1 055 and higher 1. 2 050 0.3 Carbon (calculated)- 106 EXAMPLE 6 5.7 pounds of propane vapor was charged to an apparatus of the type shown in FIGURE -1, but having increased holding capacity and. an inlet tube surrounding the pressure jet nozzle. A pressure jet of liquid mercury was sprayed into a liquid mercury pool in the manner described heretofore, thereby forming two liquid mercury electrodes. The feed stock of propane vapor was fed 1 1 into the inlet tube so that it was guided across and disposed about the liquid electrodes. Atmospheric pressure and a temperature of 50-100 C. was maintained in the reactor.

After being subjected to intermittent arcs for a period of approximately 75 minutes, 3.5 pounds of the propane vapor was found to be cracked. The weight of propane vapor decomposed per cubic foot of cracked gas was calculated from a cracked gas analysis using carbon and hydrogen balances. Then the propane consumption was calculated from the cracked gas rate which was 93 cubic feet per hour. The results obtained are tabulated below:

Table VI I Yield Per Pound of Vol. Propane Feed Cracking products percent Pound Cubic Ft.

H drogen 44. L046 8, 9 M thaneufl 5. 4 044 1. 1 Acetylene. 20. 9 1 281 1 4. 2 Ethylene. 6.3 I 002 1 l. 3 ha 1. 1 017 0. 2 Methyl acetylene. 0. 7 .015 0.1 Propylene 1. 5 033 0. 3 Propane 17. 3 3 .393 3 3. 5 Diacetylenc. 1. 3 034 0. 3 Vinyl acetylene 0. 4 011 0. 1 Butadiene 0. 4 011 0. 1 Butenes 0. 3 009 0. 1 Cds and higher." 0. 4 .014 0. 1 Carbon (calculated) 1 Acetylene yield per pound of propane decomposed was 0.462 pound and 6.9 cubic feet.

2 Ethylene yield per pound of propane decomposed was 0.152 pound and 2.1 cubic feet.

3 Propane decomposition was 60.7%.

4 Negligible.

Another quantity of kerosene was charged to an apparatus as shown in FIGURE 3. However, the circuit breaker cup 44, the hot cup 47 and the ground cup 54 were removed and replaced by a inch by 6 inch tungsten rod. The metal rod electrodes were adjusted vertically by the movable rod 55- to which they were fastened. A mercury pool electrode was employed and was located in the cone at the bottom of the reactor 38.

Two runs were thereupon made. In the second run, the mercury pool was vibrated with a thin, stainless steel diaphragm activated by a solenoid vibrator. The results are tabulated below:

Table VII Example 7 8 Electrode Description:

Ground electrodes. Mercury pool Mercury pool (vibrated). Hot electrodes x 6 tungsten 5/ x 0 iron rod rod (vertical and (vertical and adjustable). adjustable). tage:

Impressed 1,130 820. Are 700800. Arc current, Amps 2 (avg). Reactor Conditions:

Pressure, p.s.i.g.. 0.1 0.1. Temperature, 0"... 45-50 45-55.

Example 7 s Electrode Conditions:

Arc gap. inches Electrode consumption, inches/hr 0.2 0. 04 Feed Stock:

Type Kerosene Kerosene Amount charged, pounds 7 7 Consumption of Feed:

Amount, pounds... 14 13 Rate, pounds/hr 04 .035 Cracked Gas:

Amount, Cubic feet 3 2.8 Rate, Cubic feet/hr 0.9 0.8 Acctylenes in Cracked gas, percent 27 31 12 EXAMPLE 9 11 gallons pounds) of liquid heavy lube oil was charged to an apparatus of the type shown in FIGURE 1 but having increased holding capacity. A pressure jet of liquid mercury was sprayed into a liquid mercury pool in the manner described heretofore, thereby forming two liquid mercury electrodes. However, in this example, the grounded mercury electrode was suspended above the surface of the oil while only the mercury pool in the hot cup was submerged below the surface. Hence, the mercury stream passed through the oil vapors above the oil and then down into the liquid before entering the mercury pool. The following results were obtained and are tabulated below.

Table VIII Jet nozzle:

ype and size Stee1.030" diam. Positign relative to oil S111 108 1p was 1 above Arc gap, inches 3". V2 Surface Mercury pressure, p.s.i.g. 55. Length of test, minutes 70. Voltage:

Impressed 360. Are 240. Are current, amps. 100. Reactor conditions Pressure Atmospheric. Temperature, C. C. (approx). Feed stock consumed Rate, pounds/hr. 5.5. Amount, pounds 2 6.4. Cracked gas:

Rate, c.f.h 120, Total amount, cu. ft. 140.

Yield Per Pound oi Vol. Oil Cracked Cracking products 3 percent Pound Cubic Ft.

Hydrogen 51. 5 0.059 11.3 Methane 6. 6 060 1. 5 Acetylene 23. 7 349 5, 2 Ethylene 10. 0 159 2, 2 Ethane 0. 5' 009 0. 1 Methyl Acetylene.-. 1. 0 022 0. 2 Propylene 1. 8 043 0. 4 Propane 0. 1 002 Diacetylene 1. 5 043 0. 3 Vinyl Acetylene 0. 4 012 0. 1 Butadiene 0.9 028 0.2 Butanes O. 6 019 0. 1 C is; 0. 9 036 0.2 Cris 0. 5 .022 0.1 Carbon (calculated) 137 What is claimed is:

1. A process for converting hydrocarbons which comprises at least partly surrounding liquid electrodes with fluid hydrocarbons and cracking said fluid hydrocarbons by striking intermittent electric arcs between said liquid electrodes.

2. A process for converting hydrocarbons which comprises surrounding self-renewing, non-destructible, electrically conductive liquid electrodes with fluid hydrocarbons and decomposing said fluid hydrocarbons by striking intermittent electric arcs between said conductive, liquid electrodes.

3. A process according to claim 2, in which the electrodes comprise intersecting liquid streams.

4. A process for cracking hydrocarbons which comprises directing a stream of electrically conductive liquid droplets downward through said hydrocarbons, applying an electrical potential between the upper part of said stream and the lower part, and cracking said hydrocarbons by the electric arc formed between the droplets.

5. A process according to claim 4, in which the hydro- 1.3 carbons are selected from the group consisting of crude oil and fuel oil.

6. A process according to claim 4, in which the electrically conductive liquid comprises a metal.

7. A process for producing acetylene which comprises directing a stream of electrically conductive droplets through a liquid bath of hydrocarbons, applying an electrical potential between the droplets in the stream, producing electrical arcs between the droplets, cracking said hydrocarbons in 'said electrical arcs, and recovering the acetylene formed by said cracking.

8. A process according to claim 7, in which the stream of electrically conductive liquid droplets comprises a metal.

9. A process according to claim 7, in which the hydrocarbons are selected from the group consisting of crude oil and fuel oil.

5 References Cited in the file of this patent UNITED STATES PATENTS 2,353,770 Suits July 18, 1944 2,500,284 Heyrovsky Mar. 14, 1950 2,873,237 Lamberton et al. Feb. 10, 1959 10 2,878,177 Kroepelin et al Mar. 17, 1959 FOREIGN PATENTS 216,929 Australia Aug. 26, 1958 

7. A PROCESS FOR PRODUCING ACETYLENE WHICH COMPRISES DIRECTING A STREAM OF ELECTRICALLY CONDUCTIVE DROPLETS THROUGH A LIQUID BATH OF HYDROCARBONS, APPLYING AN ELECTRICAL POTENITAL BETWEEN THE DROPLETS INTHE STREAM, PRODUCING ELECTRICAL ARCS BETWEEN THE DROPLETS, CRACKING SAID HYDROCARBONS IN SAID ELECTRICAL ARCS, AND RECOVERING THE ACETYLENE FORMED BY SAID CRACKING. 